Beruflich Dokumente
Kultur Dokumente
INDEX
S. No.
1.
2.
3.
4.
4.1
4.2
4.3
4.4
4.5
4.6
5.
5.1
5.2
5.3
5.4
5.5
6
6.1
7
7.1
7.2
7.3
7.4
7.5
8
9
9.1
9.2
9.3
9.4
9.5
9.6
9.7
10
Page No.
Acknowledgement
World and Automobile
India and Automobile
Tata Group of Companies
Tata Motors Ltd.
Area of Business
Joint ventures, Subsidiaries and Associates
Research and Development
Location
Tata motors Hierarchy
Tata Motors Pantnagar
Proposed Solution
Possible further aspect in Project
In Tata Motors
BIW
Paint shop
TCF shop
PDI shop
Powertrain shop
Bibliography
2
4
5
7
9
10
10
11
12
13
15
16
20
22
23
24
25
26
26
28
28
29
29
30
31
31
31
32
33
33
33
34
35
36
37
Page 1
4 cylinder IC engine
N. August Otto
Gottlieb
(1886)
Karl Benz
Henry Ford
Since the 1900s.
in 1910
Daimler
Page 2
Public Transport
Personal Transport
War-fare
Law and order
Trade
Emergency Services
Public Hygiene
Sea Transport
Aero planes
Page 3
GRAPH 2
GRAPH 3
Page 4
Commercial Vehicles
Information technologies
CMC
Computational Research Labs
Nelito Systems
Tata Advanced Systems
Tata
Business
Support
Services
T ata Consultancy Services
Tata Elxsi
Tata Interactive Systems
Tata Technologies
Page 5
Comunication
Indian hotel
Root Corp.
Taj Air
Tata Housing
Devlpmnt Co.
Tata Realty &
infrastructure
Financial Services
Tata AIG General
Insurance
Tata
AIG
Life
Insurance
Tata
Asset
Management
T ala Capital
T ala Financial
Services
Tata Investment
Corporation
Energy
Consumer Product
Metals
Hispano Carrocera
Jaguar Land Rover
Tata AutoComp Systems
Tata Cummins
Tata Daewoo Commercial
Vehicle Company
Tata Motors
Tata
Motors
European
Technical Centre
Telco
Construction
Equipments
Engineering
TAL Manufacturing Solutions
Automotive
Tata Communication
Tata Teleservices
Tata sky
Tata Net
Nelco
Casa Decor
Infiniti Retail
Landmark
Tata Ceramics
Tata Global Beverages
Titan Industries
Trent
Westland
Chemicals
Advinus Therapeutics
Rallis India
Page 6
Tata Chemicals
Tata Chemicals Europe
Tata Chemicals Magadi
Tata Chemicals North America
Tata Pigments
Other services
4) TATA MOTORS
Tata Motors Limited is a multinational automotive corporation. A
part of the Tata Group, it was formerly known as TELCO (TATA
Engineering and Locomotive Company).
Established in 1945 by J.R.D.Tata, Tata Motors' presence indeed cuts across
the length and breadth of India. Tata Motors is India's largest automobile
company, with consolidated revenues of Rs. 1, 23,133 crores ($ 27 billion) in
2010-11.
Through subsidiaries and associate companies, Tata Motors has operations in
the UK, South Korea, Thailand and Spain. Among them is Jaguar Land Rover,
the business comprising the two iconic British brands. It also distributes Fiat
cars in India, and has an industrial joint venture with Fiat in India. With over 5.9
million Tata vehicles plying in India, Tata Motors is the country's market leader
in commercial vehicles and among the top three in passenger vehicles. It is also
the world's 4th largest truck manufacturer and 3rd largest bus manufacturer. Tata
cars, buses and trucks are being marketed in several countries in Europe, Africa,
the Middle East, South Asia, South East Asia and South America
Page 7
4d) Location
Tata Motors' plants are located at
o Jamshedpur (eastern India),
o Pune and Sanand (western India),
o Lucknow and Pantnagar (northern India).
o Tata Motors and Fiat have a common manufacturing facility at
Ranjangaon, near Pune.
being marketed in several Europe,
South East Asia,
countries
assembly operations
Malaysia,
Ukraine,
Senegal..
Africa,
Middle East,
South Asia and Australia
Kenya,
Russia,
Bangladesh,
Spain and
Page 10
Senior Management
Mr. Carl-Peter Forster
Mr. P. M. Telang
Mr. C. Ramakrishnan
Mr. Ravi Pisharody
Page 11
Page 12
DESCRIPTION OF SHOPS
ASSEMBLY SHOP
Also known as TCF Shop(TRIM CHASSIS FITTING). In this shop all the
assembly works like Engine,
Suspension, Tyres, Lights, Dashboard etc. fitting is carried out.
WELD SHOP
Also known as BIW Shop(BODY IN WHITE) .
Here the different parts are welded together and the whole structure of
the car is built.
PAINT SHOP
The TAIKISHA paint shop is the beauty parlors of the car plant. This shop
paints the car in various shades. It takes 18 steps spread over less than 10
hours to accomplish the task.
Page 13
TATA MOTORS
SUMMER INTERNSHIP PROJECT (SIP)
SHOWER LEAKAGE ELIMINATION IN
TATA ACE ZIP & TATA MAGIC IRIS
5)Shower test
The shower test is used for checking the leakage of water into the vehicle.
It is also known as water testing.
Page 14
The nozzles spray the water on both right hand and left hand side of the
vehicle at a pressure of 1.3 bar ( greater than the atmospheric pressure i.e.
1.01325bar).
The pressure in the nozzle is controlled by the flow regulating
arrangement.
The following tests are conducted on the shower.
Windshield leak
Head lamp moist/ bezzle leak
Air vent leak
Canopy leak
Door pad leak
Weather strip leak
Floor leak
Tail lamp leak
Corner trims
Roof leak
Door seal leak
Window glass run leak
Page 15
HMSL leak
STG gear grommet leak
Fire wall grommet leak
Repeater lamp leak
6june 7june
A B A B
5 12 3 2
8june
A B
5 5
9june
A B
4 1
total
4June 5June
A B A B
4 3 3 6
75
11 13
9 15 7 10 9 14 6
111
5 13
48
34
56
33
39
9.sticker missed
10.LH/RH fender leakage
2
4
0
6
2
3
2 2
7 4
2
5
5
2
5
1
7
4
8
2
6
1
12 53
2 41
57 44
44 50
50 61 51 41 51 39 39 48
FSO15
FSO-17
FSO-30
FSO-32
FSO-18
53
FSO-16
Page 16
Page 17
Glass- it has two layers which are fabricated by adhesive such as poly
vinyl beautyl (PVB).the thickness of glass is generally taken about
4.56mm and the adhesive is 0.76mm.
The glass can be used in wind shield leakage is of two types.
a) laminated
b) tempered
laminated- the laminated glass is cheaper and having cost about 200rs.
It has the property not to create sharp edges when it breaks so that it
will not harm the driver during accident.
Tempered- the tempered glass is manufactured by heating it above recrystalization Temperature and hold it for some time and cooled in some
cooling medium. It has the property not to scatter when it breaks. It is
costlier than laminated glass about 5times i.e. 1000Rs.
Page 18
a) priming- when the air stuck between the sealant pipes. It does
S.
Wind shield Causes
No. leakage
Fender leakage B.I.W , human, welding
1.
error.
2.
Profile leakage
Remedies
Automation and precise
machinery
Advanced manufacturing
processes, training of
workers
Page 19
S.
No.
1.
Harness leakage
Causes
Treatment
Grommet leakage
Improper tightening
Inspection
2.
Fitting leakage
Improper sealing or
fittings
Testing and
inspection
Page 20
S.
No.
1.
2.
Door
leakage
Door pad
leakage
Fitting
leakage
Causes
Remedies
Misalignment of fittings.
Testing and
inspection.
Hammering the
door.
Page 21
5.4)Head lamp joint leakageIt is the leakage in head lamp portion of the vehicle due to improper
fittings and some BIW problem.
The bezel gap must be within certain limit of range so that proper fitting
and no leakage can be achieved.
S.
No.
1.
2.
Head lamp
leakage
Bezel gap
leakage
Causes
manufacturing
inaccuracy(bezel gap must be
controlled)
Fitting leakage Due to improper fitting
,human error
Remedies
Precise
machinery
Testing and
inspection
Page 22
Page 23
6) Proposed Solution:
Here at TCF-1D, I was trained by the Line-supervisor to identify the
shower leakage which can be reduced by proper functioning during
fitment process.
During fitment due to human error or by some other way in trim section,
shower leakage can occour.so proper care need to be to eliminate it.
Page 24
CONCLUSIONS
After analyzing the problem, in the trim section (magic iris and tata
ace) the leakage can be eliminated within accepted limit of standards.
Page 25
7) In TATA MOTORS:
PRODUCTION SYSTEM
MANUFACTURING
PRODUCTION PLANNING
BIW(Body in white)
PAINT
POWERTRAIN
MATERIAL SUPPLY
MES(Manufacturing
execution system)
SAP
(JIT,KAIZEN,JIS)
QUALITY MANAGEMENT
7a) BIW
This shop plays very important role in framing the body shell of Nano. The press panels are
transported from Bhuj and Pune plant.
It has three main assemblies, which includes-UB(under body), ML(Main line or main frame)
and MF(metal finish) where different welding processes of
Projection welding
CO2 welding
Stud welding
MIG welding
Spot welding
are done and after that the parts are attached to the main assemblies
Page 26
SUB ASSEMBLIES
MAIN
FRAME
LINE
UNDER BODY
LINE
METAL
FINISH
LINE
PAINT SHOP
SUB ASSEMBLIES
WELD
BODY
COOLING
DRY SANDING
TCF
PRETREATMENT
ELECTRODEPOSITION
UNDERCOAT
OVEN
UNDER COAT
INTERMEDIATE
COAT (I/C)
TOUCH UP
AND
INSPECTION
ED OVEN
SOL
SEALING(UB)
SEALANT
I/C OVEN
COOLING
T/C
OVEN
TOP COAT
(T/C)
DRY
SANDING
Page 27
MECHANICAL LINE
CANOPY TEST
WHEEL ALIGNMENT
NOK
OK
REWORK
PRE DISPATCH
INSPECTION (PDI)
PAD
To
costumer
7c) TCFShop
It is the biggest of all the shops in TML,Pantnagar.
Here the painted chassis delivered from the Paint shop is accessorized
from scratch to a finish car ready for dispatch and also tested.
The car delivered by the TCF shop is completely checked with reference
to products utility quality and manufacturing quality. After several
inspections made by line operators for operational conformance and
ethical looks the Car is permitted to be dispatch from TCF shop by the
assurance of Line supervisors and operators.
The cart dispatched from the TCF shop is delivered, through drive test to
the PDI (Pre-Delivery Inspection) shop where final touching to looks is
given and the conformance of working of all the accessories is done.
Page 28
Carpet fitment.
3.
Central lock
23. Keys.
4.
Coolant filling
5.
Dents
6.
Door pad
7.
Drive shaft
8.
Engine oil .
9.
15. Fuel.
19. Hood RH
20. Horn
40. Wiper.
Being one of the most technically sound and having few of the costliest technologies
among the Asian automobiles, the culture in the Tata Motors is free, motivating and
appreciative.
Here the culture of Equality is fully nurtured all the people operator to senior level are
given equal respect through all the possible manner like same Canteen facility, same
transportation facility, same uniform among various levels.
The lesson of Time is Money & Creativity is thinking up new things Innovation is
doing new things. is taught from day 1 to all employees.
The lesson of Appreciate your colleagues work is well taught from senior level
manager to all the man-force in TML, Pantnagar.
Other nice and unique things which I observed in the Plant were:
9.1KAIZEN
The Japanese refer to Kaizen as a simple parts-movement system that
depends on cards and boxes/containers to take parts from one work
station to another on a production line.
The essence of the Kaizen concept is that a supplier or the warehouse
should only deliver components to the production line as and when they
are needed, so that there is no storage in the production area.
Within this system, workstations located along production lines only
produce/deliver desired components when they receive a card and an
empty container, indicating that more parts will be needed in production.
In case of line interruptions, each work-station will only produce enough
components to fill the container and then stop. In addition, Kaizen limits
the amount of inventory in the process by acting as an authorization to
produce more inventories.
Improving Quality
Improving Performance
Improving Delivery
Adding Flexibility
Increase innovativeness
JIT is not about automation. JIT eliminates waste by providing the environment to
perfect and simplify the processes. JIT is a collection of techniques used to improve
operations. It can also be a new production system that is used to produce goods or
services.
Page 31
Just in Sequence is one of the most extreme applications of the concept, where
components arrive Just In Time and sequenced for consumption.
The sequencing allows companies to eliminate supply buffers as soon as the quantity
in component part buffers necessary is reduced to a minimum. If not sequencing
according to scheduled variety of production, all required components must be
stocked in buffers.
For flexible production lines, as here in Tata Motors, a modern automotive assembly
line, the variety is an option to produce directly on customer orders. As soon as the
next order arrives at the work centre, the scheduler distributes the supply orders in
line with the production sequence of the final production line.
With JIS the buffer quantities are displaced upward in material flow to the
components suppliers. It is a misinterpretation of JIS to assume that all buffers will be
eliminated. Hence just the cost for buffer inventory becomes re-allocated to the
producers of the supplies. Sequencing eliminates buffers in the final assembly line by
consolidating all similar components into distributed and sequenced buffers, which
partly reside on the paths of transportation to final assembly. This strategy thus
reduces the line-side inventory buffer. However, the effect is worse when the
sequence does not get not correctly scheduled upwards or when the transportation line
gets congested.
9. 5 Elimination of Waste:
JIT usually identifies seven prominent types of waste to be eliminated:
Waste from Overproduction
Transportation Waste
Inventory Waste
Processing Waste
Waste of Motion
Page 32
Here the bill of material is a complete, formally structured list of the components that
make up a product or assembly
The list contains the item number of each component, together with the quantity and
unit of measure.
The Internship program was quite beneficial for me. It helped me in improving my
various technical skills and enhanced my knowledge in new areas.
Page 33
Teamwork
In this project I worked with line operators in order to understand the
workin process thus providing enough opportunity for proper teamwork
and coordination. This was a good experience for me as the team was
very cooperative and understanding.
Communication
Working along with the lower level operators and making them
understand the process and also getting the valuable information out of
them in a way that is comfortable to them not making them feel that they
are inferior.
Page 34
10) BIBLOGRAPHY
1.
2.
3.
4.
5.
6.
7.
8.
www.google.co.in
www.wikipedia.com
www.tatamotors.com
http://www.acmainfo.com/pdf/Status_Indian_Auto_Industry.pdf
(Graphs 2009, 15, 20).
http://www.imaginmor.com/automobileindustryindia.html (Pi
charts)
http://www.tatamotors.com/know-us/milestone.php
http://www.tata.com/businesses/sectors/index.aspx?sectid=aZ72
PXPwpaI=#Informationsystemsandcommunications
(Tata
Group of Companies)
http://www.exampleessays.com/viewpaper/17379.htm (1800 1st
automobile)
Page 35